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56WKS-4-geothermal-shallow-Geothermal-Well-GPGSığ Jeotermal Kuyu Sistemleri
56WKS-4-geothermal-shallow-Geothermal-Well-GPGSığ Jeotermal Kuyu Sistemleri
PRACTICE
GOOD
Shallow
geothermal
well systems
March 2018
These guidelines provide practical
guidance to safely drill, operate, maintain,
and abandon wells 150 metres (m) deep.
Shallow
geothermal
well systems
KEY POINTS
1.0 Introduction 4
1.1 Your legal responsibilities 5
3.2 Location 16
3.3 Cellars 16
3.4 Drainage 17
3.5 Access 17
3.6 Security 17
appendices
Appendix A: More information 33
Appendix B: Glossary 34
figures
1 Shallow geothermal well casing configuration 9
2 Wellhead construction details for self-discharging wells 10
3 Wellhead construction details for a downhole heat exchanger using
steel tube (20 mm steel tube illustrated) 11
4 Wellhead construction details for a downhole heat exchanger using
stainless steel tube (20 mm stainless steel tube illustrated) 12
5 Wellhead construction details for airlift wells 13
1.0
Introduction
IN THIS SECTION:
4
1.0 Introduction
These guidelines may apply to wells down to 250 m deep where subsurface
geothermal conditions are 20°C or more below the boiling point for depth
at ambient conditions, and the wellhead pressure is less than 5 barg.
In acidic waters or other exceptional circumstances you may need
to consider requirements beyond the scope of these guidelines.
Wells drilled in conditions more severe than those above should comply
with NZS 2403: Code of Practice for Deep Geothermal Wells and you must
construct, maintain, operate, suspend, and abandon wells 150 m or deeper
according to NZS 2403.
5
1.0 Introduction
6
2.0
Well design
IN THIS SECTION:
2.1 Casing
2.2 Wellhead design
7
2.0 Well design
Before drilling operations begin, carry out a risk assessment to make sure
risks to the health and safety of any person are eliminated so far as is
reasonably practicable.
2.1 Casing
Prepare a compliant well programme that includes all casing strings and liners
needed to:
–– prevent hole collapse
–– support drilling and permanent wellheads
–– contain well fluids
–– control contamination of subsurface aquifers
–– counter circulation losses during drilling
–– protect the well’s integrity against corrosion, erosion, or fracturing.
Figure 1 shows the casing and liner configuration for a typical well.
8
2.0 Well design
TUBING DESIGN
Design and select tubing material considering the effects which may occur at
any time or depth during the drilling or well operation from all combinations of:
–– pressure
–– temperature
–– temperature changes
–– erosion
–– corrosion.
Cement
Ground level
Conductor pipe
(where required)
Surface casing
Intermediate casing
(where required)
Production casing
Note: All casing (excluding
the liner) is required to be
cemeted from the casing
shoe to the surface.
Shallow geothermal
well casing configuration
Consider the effects which may occur at any time or depth during the drilling
or well operation from all combinations of:
–– pressure
–– temperature
–– temperature changes
–– erosion
–– corrosion.
9
2.0 Well design
Use steel materials for wellhead fittings. Cast iron is not suitable for geothermal
wells. Only use plastic fittings under appropriate conditions in low temperature
geothermal wells.
Reducing bush
Wrought cross
Master valve
(Note: not functional
if antiscalent tubing
in well – hence optional
FIGURE 2:
for such wells) Wellhead construction
details for self-
Casing discharging wells
ANSI/ASA Class 150 valves and fittings are suitable for most uses down to 150 m.
ANSI/ASA Class 300 valves and fittings are suitable for uses down to 250 m.
Above the master valve install a shaped cross or tee complying with a minimum
specification of, as applicable, BS EN 10241: Steel threaded pipe fitting or ASME
B16.11: Forged fittings, socket-welding and threaded.
The valve (or valves) will also allow vertical access for:
–– indicating nominal gauge well pressure
–– initiating well flow or boiling by introducing a compressed air line
–– wireline instrument access.
10
2.0 Well design
Bolt a minimum ANSI/ASA Class 150 steel plate to the casing head flange
with a minimum of four 10 millimetre (mm) diameter bolts. Seal the flanges with
a gasket able to withstand the temperatures and pressures encountered during
the well’s operation.
Connect the heat exchanger pipework either through the wellhead plate with
two welded (minimum 20 mm diameter) steel barrel nipples, as in Figure 3,
or, if using stainless steel pipework, through a heavy black pipe socket.
Fit steel nipples, fittings and suitably rated isolation valves to the socket connections
on the wellhead plate to connect and isolate the pipework from the well.
25 mm gate valve
20 mm sockets
25 mm minimum quenching
valve for controlling well and
for instrument entry
11
2.0 Well design
For well quenching or instrument entry, weld through the plate and fit a suitably
rated full opening 25 mm isolation valve in a vertical position to a 25 mm
minimum diameter steel barrel nipple.
Cap and plug the quench/instrument entry valve to prevent unauthorised valve
operation and to protect the valve gate from damage and corrosion.
Design the vent pipe to safely disperse the noxious gases. The height of the vent
pipe should be 3 m above the nearest building ridge line, or at least 6 m above
ground level.
If the wellhead will be below the surrounding ground level, make sure there is
enough clearance to access flange bolts and other fittings and to inspect:
–– the wellhead
–– casing head flange
–– production casing
–– annulus cement.
25 mm gate valve
25 mm minimum quenching
valve for controlling well and
for instrument entry
12
2.0 Well design
Airlift wells
Wells which discharge only with the continual aid of an air compressor should
conform to the design and valve configuration in Figure 5.
On one side of the tee (or cross), install a supply valve for controlling geothermal
fluid and connecting to a geothermal supply pipeline.
Seal the top of the tee (or cross) with a reducer through which you can thread
or weld a barrel nipple. Connect the air supply line to this nipple.
Fit a non-return valve to the air supply line connected to the wellhead.
Non-return valve
Mac union
Nipple welded
through reducer
Reducer bushing
Blowdown
valve (optional)
Casing
FIGURE 5:
Wellhead construction
Air tube details for airlift wells
Pumped wells
Design and configure wells which extract geothermal fluid by artificial lift
so that the well remains under control at all times, considering all anticipated
temperature and pressure conditions.
13
2.0 Well design
Reinjection wells
Construct reinjection wells to the same standard as production wells.
Eliminate and minimise any possible adverse impacts and fluid reinjection
interference with nearby wells.
Maintain adequate access to the well at all times for drilling rig and workover
unit servicing.
The operation and maintenance of a reinjection well should include the normal
procedures for a production well.
14
3.0
Well sites
IN THIS SECTION:
15
3.0 Well sites
Warm and steaming ground may present gas and scalding hazards to workers.
Well sites located over cavernous ground pose a hazard as the ground may
collapse exposing hot fluids.
3.2 Location
Shelterbelts, solid fences, and similar barriers to moving air can create hazardous
areas. Regularly inspect the condition of any hot ground, steam, or gas vents
on or near the well site.
The well’s location should comply with local authority and public utility
requirements where applicable.
Regulation 31 requires all wells to be located more than 1.5 m from any:
–– building
–– permanent structure
–– underground or aboveground services.
Any kind of building or structure must not enclose a well, except if ventilation
prevents hazardous gas accumulating and you ensure adequate access to
repair and properly abandon the well.
3.3 Cellars
Wellheads located below ground level must have a cellar. Cover the cellar with
a protective plate or grill that can also provide access for people to conduct
inspections.
Noxious gases can reach dangerous concentrations in deep cellars due to the
lack of natural air movement. If required, adequately ventilate and minimise
cellar depth.
16
3.0 Well sites
3.4 Drainage
Site drainage should make sure no water can enter the cellar or pool around
the well casings at ground level.
3.5 Access
Always maintain reasonable access to the well and site for workover and
emergency services.
3.6 Security
Put up fences and signs around drilling sites in public areas to discourage the
entry of unauthorised personnel.
Use barriers to prevent wells in public areas and those exposed to vehicle traffic
from damage.
17
4.0
Drilling
practices
IN THIS SECTION:
18
4.0 Drilling practices
Select well control equipment that can safely control all expected pressures and
temperatures in the well.
In certain applications you may use a diverter designed to contain and redirect
all expected pressures and flows during drilling operations. Fit the diverter with
a suitably sized and rated full opening valve on the discharge line to control the
well’s discharge.
Controls and operating equipment for the well control devices should consist
of suitably sized and rated equipment located a safe distance from the wellhead.
Before starting drilling operations, assemble the well with all its connections,
materials, and, equipment for cooling and sealing the well, ready for urgent use.
Drilling fluids
Make sure an adequate water supply is available on the site during all drilling
operations. Make sure the supply is enough for all quenching, drilling, and
cementing operations.
19
4.0 Drilling practices
Carry out your cementing programme, and use materials, to make sure the total
length of the outside casing’s annulus is full of sound cement. Make sure this can
withstand long-term exposure to geothermal fluids and the likely temperatures
you expect to encounter in drilling the well.
Pump cement down the inside of the casing and circulate it back to the surface
via the casing/drill hole or casing/casing annulus. Do not interrupt the cement’s
pumping and circulation.
Regulation 33 requires you to fully cement into place all casing strings, except
open-hole slotted liners. Where applicable, cement casings with a uniform
quality cement grout which fills the annular space between the casings and
extends from the shoe to the surface.
You must make sure that adequate first-aid facilities and first-aid equipment
is available on site at all times. You must post notices indicating the first-aid
equipment’s location(s).
The Health and Safety at Work (General Risk and Workplace Management)
Regulations 2016 require PCBUs either train workers to administer first aid or
provide access to other trained first aiders. In the context of drilling operations,
make sure that there is at least one certified first aider on site trained in
resuscitation techniques.
Before starting work, make sure workers are aware of the hazards and risks
normally associated with drilling and hot geothermal fluids.
20
4.0 Drilling practices
All workers on a well site where there is a drilling rig must wear, and use,
appropriate PPE. If hazardous gases are present on site, make sure gas
detectors and breathing escape apparatus is available and fully train workers
to use this equipment.
If there is any risk of a fall, or for rescue readiness, make sure workers wear
fall arrest harnesses with appropriate attachment equipment and anchors
appropriate to the task. Workers should be hooked on in all situations where
there is a risk of a fall.
Regulation 31 requires that after drilling starts every well must be permanently
identified by a sign on or near the well clearly identifying the well’s name and
number by letters and numbers at least 30 mm high. The sign must be visible
from ground level.
The information you need to record and include in a summary report after
completing drilling operations is in WorkSafe’s fact sheet Consents and
Reports Required by the Geothermal Energy Regulations 1961 available at:
worksafe.govt.nz
The information you should record and keep in a daily log is:
–– well name, number, and location
–– elevation of the kelly bushing, rotary table, or derrick-floor above mean
sea level and above ground level
–– for each 24-hour period:
-- date
-- drilling depths at the beginning and end
-- distance drilled
–– current diameter of the hole
–– current operation
–– completion data on the final daily drilling log
–– penetration rates or drilling breaks
–– well site measurements
–– cored intervals
–– details of any casing operations and any subsequent modifications
21
4.0 Drilling practices
22
5.0
Drilling
practices
IN THIS SECTION:
23
5.0 Well operation and maintenance
Regulation 26 requires:
–– The well, and the equipment used in the geothermal work, to be
maintained to prevent damage or risk of damage to the well and the
equipment, and to prevent danger to people on the site, or in the vicinity,
of the geothermal work.
–– All geothermal work where the heat discharged by any well is likely
to exceed 20 terrajoules measured above 0°C over any period of 12
consecutive months must be carried out in accordance with NZS 2402P
Code of Practice for Geothermal Heating Equipment in Rotorua (except
Parts 2, 6, 7, and 10).
Make sure there is a clear and safe means of egress from the wellhead area
for workers involved in opening valves to discharge or control the well flow.
For discharging wells, fully open the master valve before opening the supply
valve to allow the well to flow.
Immediately before discharging a well, fully close the control valve before
opening the master valve. Partially open the master valve to pressurise the
downstream pipework so that you can check the pressurised control valve for
leakage. Fix any leaks.
Do not use a master valve to throttle a well flow and, in particular, do not use it
to close in a flowing well except in an emergency situation. If the control valve
does not fully seal, close it as much as possible before closing the master valve.
Following the opening of a well, inspect, for correct performance, all pressurised:
–– pipes
–– valves
–– flanges
–– fittings
–– equipment.
24
5.0 Well operation and maintenance
If you observe any defects or leaks, close the well and fix the defects and leaks
before reopening the well.
Following the well’s opening, monitor the wellhead and associated pipework
during the initial four hours. A typical inspection frequency is:
–– one minute
–– five minutes
–– 10 minutes
–– 30 minutes
–– one hour
–– two hours
–– four hours.
Close a discharging well by fully closing the supply valve downstream of the
master valve before closing the master valve. After closing the master valve,
blow down the pressurised pipework downstream of the master valve and check
for leaks past the gate. If there is leakage through the master valve, operate the
valve to try and affect a seal.
You may install flow-reduction devices on the wellhead to restrict flow from the
well. Fit an orifice plate downstream of the master valve or a pipe restriction
downstream of the supply valve.
Determine whether you should maintain the wellhead in a hot or cold condition.
Wells “on bleed” require regular inspection to make sure the control devices
remain clear and that the released wet gas does not cause external corrosion
of the wellhead or pose a risk to people.
Adequately design bleed discharge lines and terminate them at some distance
from the wellhead to avoid:
–– discharging fluids corroding the wellhead components
–– hazardous gas concentrating around the wellsite.
25
5.0 Well operation and maintenance
Keep the site area clear of any plant growth which could enhance corrosion
or inhibit access to the well or the erection of workover equipment.
Wellhead maintenance
Inspect and make sure the wellhead and it’s steel surfaces are substantially free
of corrosion. Remove and assess the depth of corrosion if it has formed and carry
out maintenance. Monitor outer casings, outer cement, annulus cement, and
outer casings for corrosion and deterioration and any defects. Repair them as
soon as practicable.
If protective paint systems require renewal, remove all defective areas by wire
brushing or, if necessary, by sandblasting, before applying fresh coatings.
If severe casing corrosion is apparent or you suspect it’s on the near outer
casings, remove the outer casings until you can expose sound casing. Sandblast
and paint the exposed casing and reinstate the outer casings, outer cement,
and annular seal.
Make sure a suitably qualified and experienced person carries out any
maintenance.
Inspect all valves, fittings, glands, and flanged fittings for leaks of geothermal
fluid. Repair them as soon as practicable.
If possible, regularly monitor the wellhead pressure. Carry out wellhead pressure
monitoring on a six-monthly basis, or more frequently if reservoir conditions are
not static.
Quenching
If quenching is required, carry it out in a manner which minimises the risk
of damaging the well casing.
If you are quenching a well with cold water, control initial flow rates at a level for
a period of time and then gradually increase the flow until the well is off pressure.
Slowly reduce any wellhead gas pressure by bleeding the gas from the well either
before or during the quenching operation.
If you are using town supply water to quench a well, install two tested non-return
valves on the supply line to prevent backflow of geothermal fluid in the water
supply line. Consult with the local authorities to determine if you require any
additional controls.
Prominently post a warning sign on the water supply valve instructing any
unauthorised people not to shut off the supply of water to the well once a well
is on quench and temporarily under control following a blowout or repair and is
left unattended until permanent repairs can be made.
Wellhead repair
Before repairing or replacing wellhead components, gradually quench the well
keep it in a totally quenched condition for twice the estimated period of time
required to carry out maintenance.
26
5.0 Well operation and maintenance
If, while pumping water into a well, it cannot be cooled enough to prevent well
flow for twice the required time to install or change wellhead components, then
plug the well with a:
–– retrievable packer
–– drillable plug, or
–– competent, pressure-tested cement plug set inside the inner cemented casing.
Fit the master valve before reinstating outer casings and annulus cement.
If the well has been quenched to replace a section of casing that requires
welding, then keep the well fully quenched in a way which prevents cold water
coming into contact with the casing section being welded.
Avoid damaging adjacent sections of casing during any casing section cutting
or removal.
Install well control equipment on any well which has any potential to discharge
during any phase of the workover.
The output of wells may decline over time due to mineral deposits forming,
including calcite in the production casing. Calcite forms when geothermal fluid,
containing dissolved carbon dioxide, boils. Calcite’s deposit rate depends on
the chemistry of the geothermal fluid, which varies from well to well, and on
the mass flow rate from the well.
27
5.0 Well operation and maintenance
Take proper precautions in both handling and using acid solutions and other
hazardous products. Make sure safety data sheets are available on site for all
hazardous materials you use.
Improper chemical cleaning can lead to severe casing corrosion resulting in:
–– well failure
–– contamination
–– damage to surface pipework or mineral baths.
Install and use good quality equipment according to sound engineering practice
to prevent mineral deposits forming.
Use suitably designed disposal equipment to take the geothermal fluid at all
times, without overflow or water carry-over from the gas vent and without
causing a risk to people nearby.
28
6.0
Well
abandonment
IN THIS SECTION:
29
6.0 Well abandonment
Regulation 33 requires that you do not recover a casing if its recovery exposes
any abnormal pressure or lost circulation zone. If practicable, you must
completely fill wells with uniform cement grout and place it into the well using
drill pipe, or other suitable pipe, so the initial placement of the grout at the
pipe’s bottom end starts at the deepest shoe of cemented casing.
If practicable:
–– take wells off pressure by quenching
–– ream the well to the production casing’s internal diameter to the production
casing shoe’s depth.
After placing the cement in the well, including within the casing, treat the
well as still being capable of discharging and shut it in with a valve or BOP.
After withdrawing the drill string, top the cement up to ensure there is a
continuous cement plug from the production casing shoe to the surface.
Select cement with the smallest deterioration over time. Add appropriate
additives such as friction reducers, and cement retarders as you require.
A common cement slurry density is in the range of 1.70-1.82 kg/l.
If fluid or gas leakage is obvious from the casing annulus, attempt a grout
squeeze after packing off and plugging much of the open-hole section with
poorly sorted sand or gravel.
30
6.0 Well abandonment
You can use bull heading to force the cement up the annulus, however, make
sure to control pipe pressures to avoid hydro fracturing the open-hole section
immediately below the casing shoe.
After abandoning the well, remove the wellhead and cut the casing at a minimum
depth of 0.3 m below ground level.
31
Appendices
IN THIS SECTION:
32
Appendices
For information and guidance specifically about electrical or gas safety visit WorkSafe’s website:
www.energysafety.govt.nz or call 0800 030 040.
Standards
API Spec 5CT Specification for casing and tubing
BS EN 10216 Seamless steel tubes for pressure purposes. Technical delivery conditions.
Non-alloy steel tubes with specified room temperature properties
Guidance
Introduction to the Health and Safety at Work Act 2015
WorkSafe New Zealand worksafe.govt.nz
Excavation Safety
WorkSafe New Zealand worksafe.govt.nz
33
Appendices
Appendix B: Glossary
TERM DEFINITION
Airlift wells Wells which discharge with the continual or near continual aid of an air compressor.
Blowout An uncontrolled flow of steam, water, gas or rock material at the ground surface either inside
the well or escaping from the well at depth.
BPD (Boiling point Representing a column of pure water at its boiling (saturation) temperature corresponding
for depth conditions) to the pressure at every depth.
Cellar An excavation around the top of the well to accommodate part of the wellhead.
Conductor pipe The large diameter, very shallow pipe sometimes installed before drilling starts, used to retain
surface material against collapse or washout, and to elevate returning drilling fluid to above
ground level.
Diverter A well control device consisting of sealing elements compressed in a cylindrical body mounted
on a well and operated by hydraulically or air activated cylinders, with piping to direct the
discharge from a well at a safe distance during drilling operations.
Downhole heat Pipework installed in a well for the purpose of extracting heat. Circulation may be maintained
exchanger by thermosiphon, mains pressure, or circulation pump.
Drilling Includes workovers and all well site activities associated with rigging up and rigging down.
Intermediate casing If subsurface conditions require, the casing installed to enable target depth to be reached
for that stage of the well.
Liner A casing having openings for the production or injection of fluids, and installed in the drilled
hole to prevent collapse of the formation or entry of debris into the well.
Low pressure steam Steam-producing wells with a measured shut-in wellhead pressure of less than 0.35 barg.
wells
Pressure Gauge pressure (that is, pressure above ambient) unless specified otherwise.
Note: As steam tables normally use absolute values, add atmospheric pressure to gauge pressure
before using the tables.
Production liner A casing string installed to protect the hole or other casings from the corrosive or erosive
effects of fluid flow. Depending on its purpose, this liner may be cemented, or free to expand
with increase in temperature.
Pumped wells Wells that are fitted with artificial lift devices, which may be surface- or downhole-mounted,
to enable geothermal fluid to be extracted.
Quench The injection of cold liquid into a well to condense or prevent the formation of steam,
or to reduce temperatures for other purposes.
34
Appendices
TERM DEFINITION
Reinjection well A well that is drilled for the purpose of re-injecting geothermal fluids into the ground.
Self-discharging Wells which discharge geothermal fluids without the aid of continued artificial lift.
wells
Surface casing The first casing installed in the well which supports a drilling wellhead.
Wellhead A set of valves and other pressure-rated components, connected to the top of the well and used
to contain the well fluids.
35
Notes
Disclaimer
WorkSafe New Zealand has made every effort to ensure the information contained in this publication
is reliable, but makes no guarantee of its completeness. WorkSafe may change the contents of this guide
at any time without notice.
This document is a guideline only. It should not be used as a substitute for legislation or legal advice.
WorkSafe is not responsible for the results of any action taken on the basis of information in this
document, or for any errors or omissions.
First edition published in 1996 by the Occupational Safety and Health Service
Reprinted in 2002 by the Occupational Safety and Health Service
Second edition revised in 2005 by the Department of Labour
worksafe.govt.nz
Except for the logos of WorkSafe, this copyright work is licensed under a Creative Commons
Attribution-Non-commercial 3.0 NZ licence.
In essence, you are free to copy, communicate and adapt the work for non-commercial purposes,
as long as you attribute the work to WorkSafe and abide by the other licence terms.
WSNZ_2916_Mar 18
ISBN 978-1-98-852761-1 (online)